Parts Replacement; Safety Instructions; Initial Preparation; Removal Of Burner Assembly - Vaillant ecoMAX SERIES Instructions For Installation And Servicing

9 Parts replacement

Ensure that ALL regulations are observed.

9.1 Safety instructions

The following safety instructions are to be followed
when installing replacement parts!
Important:
Before starting any maintenance work:
Isolate the mains electricity supply by dis-
connecting the plug at the socket outlet (if
there is only an isolating switch remove the fuse
from the switch).
• Turn off the gas supply at the gas service valve fitted
to the boiler.
• When removing any water carrying components ensure
that water is kept away from all electrical components.
• Always use new seals and O–rings when replacing parts.
• Always test for gas soundness and always carry out
functional checks after any service work and after
exchanging any gas carrying component.
• Always check earth continuity, polarity and resistance
to earth with a multimeter after any service work and
after exchanging any electrical component.

9.1.1 Initial preparation

• Turn off the boiler.
• Isolate the electrical supply to the boiler.
• Remove boiler bottom cover.
• Turn off the gas service valve.
• Turn off the boiler CH service valves.
• Turn off the cold water inlet service valve (ecoMAX 800).
• Remove front case
• Lower electronic control box.
• Release central heating water pressure by draining the
boiler from the drain points provided. (This needs only
to be carried out when detailed in these instructions).
• After installing replacement parts, recommission and
check boiler function as described in commissioning
section.
Note:
The boiler is fitted with a combustion analysis
test point. A suitable combustion analyser can
be connected at this point to establish the com-
bustion performance of the boiler.

9.1.2 Removal of burner assembly

• Remove screw and disconnect air inlet pipe.
• Disconnect gas supply from gas valve by undoing union.
• Disconnect HT lead and earth lead from spark electrode.
• Remove five nuts from burner manifold.
• Disconnect two electrical connections from fan and
gas valve.
• Pull forward complete burner, gas valve and fan assembly.
• Remove burner, gas valve and fan assembly from boiler.
Instructions for installation and servicing ecoMAX

9.2 Replacement of burner

1
Fig. 9.1 Replacing the burner
• Turn off boiler.
• Remove front casing.
• Lower control box.
• Remove burner, gas valve and fan assembly as pre-
viously detailed.
• Remove 4 screws (1) securing burner to burner manifold.
• Fit new burner to manifold using the new sealing gas-
ket supplied, ensuring that the notch in the burner ali-
gns with the burner viewing window.
• Reassemble in reverse order.
• Recommission boiler as detailed.

9.3 Replacement of fan

• Turn off boiler.
• Remove front casing.
• Lower control box.
• Remove burner, gas valve and fan assembly as pre-
viously detailed.
• Remove 4 screws (1).
• Separate gas valve and fan assembly from burner
manifold (2).
• Remove 2 screws (3) securing gas valve to fan.
• Fit gas valve to new fan using the new sealing gasket
supplied.
• Refit gas valve and fan assembly to burner manifold
using the new sealing gasket supplied. Equally tighten
the four screws (1) to ensure a good seal is made.
• Reassemble burner, gas valve and fan assembly in
reverse order.
• Recommission boiler as previously detailed.
Parts replacement 9
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